International Conference Structural integrity of welded structures

Nondestructive assessment methods of the remanent life in

a metallic structure under creep behaviour
N. Pasca, A. Murariu, M. Iacob
National R&D Institute for Welding and Material Testing ISIM Timisoara
Abstract. This paper present the damage state and remaining life assessment for a metallic structure from
16Mo5 steel, using the nondestructive method of metallographic replicas and the assessment of this replicas
using the A parameter and VGB 507 standard. For results interpretations we used the expert system iRiS
Power, which allowed to determinate the steel grade degradation and remanent life estimation.
Key words: A parameter, expert system, remanent life, creep

1. Introduction
The paper presents the degradation state assessment for a weld metallic structure using the
nondestructive metallographic replicas method. The components subdued under duration
loadings, thermal and mechanical sustain microstructure degradation in service period,
degradations that will finally lead to failure.
The thermo mechanicals loads conduce to apparition of creep phenomenon which
conduces in time to microstructure modification, the carbide increase and distribution in
inside and to grains limit, affecting the strength characteristics of the material. To analyse
these type of structure modification can be used metallographic replicas methods. In
general, metallographic replicas can be used for:
(a) microstructure study (creep cavities, grain size etc.) using the surface replicas
and optical microscopy;
(b) examination and identification of small secondary phase particles from
extraction replicas techniques in order to determine the distances between particles.
1.1. Surface replicas
Replicas can provide information on the current status of the material they are made the
components. The method is nondestructive and can be applied in any area accessible of
structure. The replicas providing only relevant data to the component surface examined.
Standard procedure
This procedure defines the requirements for making adequate surface replicas for
metallographic examination. This procedure can be successfully applied in assessing the
microstructure of components working at high temperatures in creep area, according to
ASTM E 1351-01 [1].
Interpretation
Surface replicas are suitable to examination with an optical microscope with a
magnification of 500 times. If the examination is performed using a transmission electron
microscope, are necessary specific replicas partly immersed in acetone. Dissolution of
acetate film leads to a positive replicas image for examination under a microscope [2].

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To assess the state of degradation of a material, it must be analyzing the replicas by

qualitative techniques and quantitative techniques.
1.2. Qualitative techniques
Accurate assessment of the state of degradation, using qualitative techniques, depends on
knowing the initial state of the material (to manufacture). Data presented in Table 1 serve
to situate the microstructures state where the material examined is, compared to initial state
(if known or distinct).
For qualitative assessment of metallographic replicas we can use several classifications, of
which mention: VGB [2, 3], Nordtest [4], Neubauer [5], ISQ [5].
a) State of Degradation
Creep damage - cavitations or cracking - must be assessed correctly both for fitness for
service evaluation and for life prediction. In the case of weldments, it is an important part
of damage assessment to determine the microstructural region in which damage occurs. If
several regions are damaged, they should be assessed separately.
b) Damage Classification
Table 1 shows the degradation classes after the classification criteria proposed by various
authors [5]:
Table 1: Degradation Classes
Degradation
Without Without
Isolated
Scale
Degradation Cavities Cavitation
Neubauer

Oriented Microcracking Macrocrack

Cavitation

Nordtest

2.1, 2.2, 2.3

3.1, 3.2, 3.3

4.1, 4.2, 4.3

VGB-TW 507

2a, 2b

3a , 3b

0/1 , 1

1/2 , 2

2/3 , 3, 3/4

ISQ

1.3. Quantitative Techniques

For characteristic zones of welded joints has been validated a quantitative assessment
method of cavities [5]: A Parameter.
The 'A' parameter is defined as the number fraction of cavitating grain boundaries
encountered in a line parallel to the direction of maximum principal stress.
The 'A' measurements are made with an optical microscope, preferably using green
monochromatic light and a 40X objective and 10X or 12.5X eye-pieces fitted with a crosshair graticule, giving a magnification level of 400X to 500X.
With reference to Figure 1, Boundaries A, B and C are DAMAGED and boundaries D, G
and J are UNDAMAGED. Boundary intersections H and I are both counted, and must have
the same damage state (in this case UNDAMAGED) since they are on the same boundary.
Intersections E and F are examples of triple point intersections classified according to the
`majority vote', that is E is damaged and F is not.
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If the number of damaged boundaries is ND and undamaged boundaries NU then the

number fraction of cavitating boundaries (parameterA), is simply defined as: [5]:
A=

ND
NU + ND

(1)

The length of the traverse (L) and the grain size, defined by the mean linear intercept, l,
calculated:
l = L / (NU + ND)

(2)

Figure 1. Rules for A parameter determination [5]

In order to achieve the necessary precision in A parameter value, it is usually necessary

to count a minimum of 400 grain boundaries, achieving this by a series of parallel
traverses, separated by two fields of view.
b)

Calculations based on the A parameter

In the absence of a crack, the following relationship may be used:

n

1
4

LF = 1 1 A

(3)

and

1 LF
t reman = t serv

LF
where:
- LF = life fraction consumed = tserv/tr
- A = number fraction of cavitated grain boundaries, measured on a line parallel to
the principal stress axis;
- n = stress exponent for creep;
- = primary hardening exponent;
- = r/s;
- r = creep rupture strain;
- s = mtr = Monkman-Grant parameter;
m=minimum creep rate
- tr = creep rupture life;
- tserv = service life to date.
3

(4)

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If the damage is uniform through the section, then this time is the time to failure, if the
damage is localised, this time is the time to crack initiation.
Values of the parameters n, are dependent on material, stress and temperature.

2. Metallic structure analysis

The structure analysis has the follow technical characteristics:

Material:

16 Mo5 STAS 2883 /3-88 (W1.5423)

Inside Diameter:

D = 6200 mm

The length calculation of the cylinder element> L = 18500 mm

Equipment volume (nominal):

V = 697000 litres

The design thickness (steel 16Mo5

according to STAS 2883/3-88):

Sp = 25 mm

Additions to operating conditions

(liner steel X6CrAl13, W1.4002):

C1 = 3 mm

Maximum allowable pressure:

PS = 0,5 MPa

Operating Pressure:

0,4 MPa

Hydraulic test pressure (up):

1,45 MPa

Maximum allowable temperature:

TSmax = +485C

Minimum allowable temperature:

TSmin = +15C

Maximum operating temperature:

Tmax = +475C

Minimum operating temperature:

Tmin = +30C

Number of operating cycles (at 26.07.2010):

1415 cycles

Number of operating hours (at 26.07.2010):

72.600hours

3. Quantitative assessment of material degradation

For the assessment of material degradation were performed metallographic replicas from
28 zones of the metal structure.
The metallographic replicas were analyzed to optical microscope and were performed
pictures of the microstructures at 500x magnification, in examined zones. On images
obtained were determined the number of grains damaged and the number of grains
undamaged along the 22 parallel lines to the direction of maximum principal stress, the
lines crossed the grains limits. For each replica, using the expert system Figure 2, was
calculated A parameter according to relations (1, 2). After microscopic analysis no
cracks were found in the material, so for remanent life calculation in the expert system has
the option which use relations 3 and 4 (figura 3).
The parameters used in calculus relations (3, 4) were chosen using expert system,
depending on material and operating conditions.
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Figure 2. System expert capture with dates

introduce for A parameter calculation and the
results obtained

Figure 3. System expert capture for calculating t

he life time prediction

4. Qualitative assessment of material degradation

According to VGB 507 standard and Neubauer assessment, the metallographic replicas
analysed to 500x were compared with standard images. In figure 4 is shows a comparison
between the level of degradation according to VGB standard and one replica (mark V5)
extracted from the base material analyzed at 100x and 500x magnification.

Figure 4a: V5, MB0

[Nital 3%, 100]

Figure 4b: Standard image according to

VGB 200X [2]

Figure 4c: V5, MB0

[Nital 3%, 500]

Figure 4d: Standard image according to VGB

500X [2]

Figure 4: Qualitative degradation assessment with metallographic replicas method

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5. Results and conclusion

Following a quality assessment of a material degradation using the metallographic replicas
method and results comparison with standard images showed in VGB 507 respectively
Neubauer classification, it was demonstrated the fact that the material is in 2a degradation
state according to VGB, respectively in B degradation state according to Neubauer, which
means the fact that the material is exposed at creep, however the cavities are isolated.
As a result of a quantitative assessment of metallographic replicas were determined values
of A parameter ranges between 0, 08 and 0, 14.
Using the expert system, based on equations (1, 2, and 3) was estimated life fraction
consumed. The parameters values n, and are material function, loading and
temperature. These parameters have been chosen using the expert system, by SP 249
module calculus.
As there are many A parameters determinations assessed on replicas taken from
different structures zones, for global evaluation of results, these have been statistic
processed, using the expert system. It was estimated a value of a life fraction consumed of
approximate 0, 65 for the structure analyzed on Figure 5. Applying the equation 4 has
been calculated the remanent life of material until next re-evaluation of material,
approximate 39.000 hours. Also has been stated the fact that the obtained results refers
only to examinated steel 16 Mo5 mark, afferent to analyzed metallic structure not taking
into consideration the possible material non-detected defects.

Figure5. System expert capture to determine the life fraction consumed

Based on the obtained results we can summarize:

o Based on the results obtained through qualitative assessment of metallographic
replicas, the examinated material fits in the 2a degradation class, according to VGB
rating, respectively class B according to Neubauer rating.
o As a result of an quantitative assessment of metallographic replicas using the A
parameters method, we estimate that 16 Mo 5 steel from the composition of the
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metallic structure can be used at designed parameters maximum 39.000 hours,

until the next material state re-evaluation.

References:
1.
2.
3.
4.
5.

*** ASTM E 1351-01- Practice for Production and Evaluation of Field

Metallographic Replicas
*** VGB 507 Guideline for the Assessment of Microstructure and Damage
Development of Creep Exposed Materials for Pipes and Boiler Components
*** TRD 508 Guideline for the Assessment of Microstructure and Damage
Development of Creep Exposed Materials for Pipes and Boiler Components
*** NORDTEST Project - Reference micrographs for evaluation of creep damage
in replica inspections, 1992
Brear J. M. , Jovanovic A. , SPRINT SPECIFIC PROJECT SP 249
Implementation of Power Plant Component Life Assessment technology using a
Knowledge Based System ERA Tech. UK and MPA Stuttgart, Final Report, 1992.